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Overhauling the front forks
Note
It is advisable to loosen the top cap (7) when the fork leg is still fitted to the motorcycle.
Note
The specific tools for the revision of the fork, are described in Sect.*3 -*4, Specific tools for the frame.
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Loosen the spring preload adjuster before unscrewing the plug (7).
Unscrew the top cap (7) complete with the rebound damping adjuster.
Disassembly of the front fork
Restrain the counter nut (13) with a hex wrench.
Using another hex wrench, unscrew the plug (7), with its seal, from the cartridge (8).
Unscrew the counter nut (13) up to the final threads on the damper (8).
While restraining the spring (9) with one hand, withdraw the bush (20) sideways and then slowly release spring (9).
Slide off the spring (9).
Slide the preload tube (12).
Drain the oil from inside the leg by pumping with the outer tube (18) and the damper cartridge (8).
Warning
This movement generates pressure so that the oil will be rapidly expelled from the fork leg.
Aim the jet of oil into a previously prepared container and avoid contact with fork oil.
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Block the fork tube/calliper unit (6) with a vice provided with protection jaws.
Unscrew the compression damping adjuster (3).
Remove the adjuster screw (3) and recover the seal (4).
Withdraw the damper assembly (8).
Slip the dust seal (15) off the outer tube (18), prising it off with a screwdriver.
Remove the circlip (17).
Important
Take care not to damage the fork tube - calliper unit (6) and the seat of snap ring (17) in the outer tube (18).
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Remove the outer tube (18) from the fork tube - calliper unit (6), pull sharply outwards repeatedly to gradually displace the bottom bush (26).
Insert the tip of a screwdriver in the slit in the bush (11) and open it up sufficiently to slide the bush off the fork tube - calliper unit.
Remove the following parts from the inner fork tube:
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bottom bush (26);
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collar (27);
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Sealing ring (21);
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circlip (17);
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dust seal (15).
Inspection of the front fork
Place the spring on a flat surface and measure the free length (L).
Service limit:
270*mm.
Replace the spring if the length is not within the specified limit.
Inspect the outer surfaces of both fork inner tubes and the internal surfaces of both outer tubes. They must be free from scoring, steps, or dents.
Check that the outer tubes are straight:
maximum allowed error 0.10*mm.
Whenever the inner tube is removed from the sleeve it is good practice to replace the bottom bushes (20) and (26).
Check the collar (27) for distortion in the area indicated. Replace if distorted.
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